Digital Way, tool wear and breakage monitoring system

WattPilote® Accostage

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Tool contact detection system

Guaranteeing:

• The automation of any type of tool contact,
• The quality and precision of the produced items,
• Optimisation of the tool contact time,
• Safety for the operators,
• Protection of the machines.

The WattPilote Accostage is a tool/part contact detection system based on the measurement of motor power. This is a reliable system, simple to set up on any type of machine. Information are collected from the electrical cabinet, eliminating the need for a sensor to be installed at the machining head. The measurement of electrical output means that the apparatus is not affected by environmental influences (like temperature, noise, vibration, etc.).

A set of parameters determines the detection characteristics for a given power threshold during tool contact on a part for example.

The programming of the parameters and the fine-tuning are carried out using a PC: a configuration mode makes it possible to download the parameters for each tool. An acquisition mode displays the power and state of the apparatus in real time. As soon as the fine-tuning process is complete, the PC is disconnected and WattPilote Accostage becomes fully autonomous.

Operating principle :

WattPilote Accostage initially memorizes the average power consumed by the machine (this average corresponds in general to the no-load power). It then compares the instantaneous power with that previously memorized. Detection is activated if, for a given time, this power exceeds the average power consumed by the machine, increased by a threshold entered by the operator (as a percentage or an absolute power value).

Performances :

• Measurement precision of 0.2 ‰
• Monitoring of 8 different tools
• Detection of ultra-fast phenomena (5/1000 sec.)
• Works with all types of spindles

Two types of verification are simultaneously carried out during detection operations (irrespective of the operation). These concern the maximum and minimum power thresholds.
The maximum threshold is used to detect abnormal consumption by the machine (indicating collision or tool breakage). The machine is immediately stopped.
The minimum power threshold is an important aid to verify that the tool or the part being machined is rotating properly. Alarm is given if the spindle is not rotating properly. Combined with these two checks, a "release advance" output blocks the advance in the event of an occurring malfunction. This output is also deactivated when the reference power measurements become unstable (non-stabilized spindle speed).

Characteristics

WattPilote accostage :

• Characteristics
• Inputs: industrial inputs, opto-coupled, 24V DC type 2
• Outputs: static 24 V DC (transistors)
• Mounted directly onto a symmetrical DIN rail (EN50 023)
• Dimensions: length 124 mm, width 105 mm, height 92 mm

PC connection cable :

• Screened, with metal caps
• RS232/RS422 connection
• Reference: WL-C04

WP_ACCOST software:

• Runs on a standard PC
• Linked via RS232 serial connection
• Windows 95 or 98 operating system

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